senior design i peer review january 20 th, 2006 po6208 – arc works sports bottle sponsor: arc...
TRANSCRIPT
Senior Design I Peer ReviewJanuary 20th, 2006PO6208 – ARC Works Sports Bottle
Sponsor: ARC Works of Monroe County
Team Members: Team Leader George Gooch, Chris Donati, Drew Stone-Briggs, Hui Kim, Mike Hayden, Mike Levis, Jeff Coppola, Bill Lucas
Mentors: Dr. DeBartolo (ME) and Dr. Marshall (IE)
Project Overview The Following is a Basic Overview for the
Purpose of the Project: Faster and more automated production Less rejected assemblies More convenient and ergonomic work stations Better inventory management
Background, to Date Met with sponsor to discuss objectives Created needs assessment based on meetings Began conceptualizing solutions
Design Team - ‘Brainstormed’ different options for each process Inventory Management Team - Began working with inventory
program
Project Overview (Cont.) Basic Assembly
Finished Enclosure
Components
Closure (Various Sizes) Adapter Straw (tube)
(Various Lengths)
Project Overview (Cont.) 1st Operation: Straw Cutting
Process Machine
10 Straws at once are inserted into the top of the automated straw cutter. The machine cycles, cuts the straws and they drop through into a box.
Project Overview (Cont.) 2nd Operation: Adapter / Closure Insert
Process MachinesClosures are placed in the bottom fixture and Adapters are placed in the top fixture of one of two style manual presses. The presses are cycled to create the Closure / Adapter Sub-assembly.
Project Overview (Cont.) 3rd Operation: Final Assembly Press
Process Machine
Closures / Adapter Sub Assemblies are placed in the top fixture of the automated press. Straws are placed in the bottom fixture. The machine is cycled to create the final assembly.
Design Ideas for the Closure Tube Assembly Process
Improve tube cutter loading Combine all assembly steps Increase productivity using automated
feeders Improve ergonomics & safety Add electronic parts counter
Tube Cutter Improvement
Modifying vs. replacing existing equipment Standardizing machine components Expanding the capacity of the tube holder Adding electronic parts counter Improving ergonomics
Tube Cutter Improvement
Manual Tube Feeding Concept
Tube Cutter Improvement
Discussion: Methods for improving throughput,
especially loading of tubes into cutter Manual vs. Automated Increase batch size
Assembly Process Improvement
Pin Style Automated Press Discussion: Pin tube support
Sliding Adapter Fixture Press Discussion: Closure Interference,
Fixture Alignment, Adapter Orientation
Assembly Process Improvement Two Stage CTA Press
Discussion: CTA Removal, Rotation
CTA Process w/ Magazine Feeder Discussion: Alignment
Feeding Concepts Automated Feeding
Discussion: Cost, Complexity, Durability, Clip Manufacturability
Also… Closure?
Feed Escapement
Tube Adapter
Current Inventory Issues Sponsor’s concerns include:
Tracking sub-assemblies through the system Running different types of reports such as sales and
inventory The ‘Writing Assistant’ function of Great Plains Cycle counts Using Great Plains to help with Safety Stock and reorder
points Inputting data as a transfer of materials rather than an
adjustment Subtracting on-hand components from the system when a
kit is completed Utilizing the software to set up a backorder system to fill
shorted kits
Current Inventory Issues
Discussion:
Metrics to weigh improvements against
How to relate this issue to IE criteria vs. just teaching them how to use the system
How much time should we put into learning the system vs. the amount we can actually help them in a way that is significant in our senior design
Goals Desired Outcomes – Stage 1 (Winter)
Develop an understanding of areas needing improvement Finalize design concepts that meet customer goals Learn the current inventory management system Come to an acceptable design
Develop project BOM and estimated costs
Desired Outcomes – Stage 2 (Spring) Faster production by the ARC Works team Less backorders and established safety stock Fewer rejects Higher satisfaction of workers
This material is based upon work supported by the National Science Foundation under Award No. BES-0527358.Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author and do not necessarily reflect the views of the National Science Foundation.
This material is based upon work supported by the National Science Foundation under Award No. BES-0527358.Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author and do not necessarily reflect the views of the National Science Foundation.
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